Section 12 BODY AND INTERIOR Contents Introduction 1. General Description. or 12 13 14 Instrument Panel and Instrument Cluster. ‘Seats, Seat Belts, and Interior Ventilation, Heating, and Air Conditioning Body 2. Maintenance, 3. Troubleshooting 4. Interior 4a 42 43 44 45 46 Instrument Cluster and Instrument Panel Removing and Instaling Instrument Cluster Removing and Instaling Instrument Panel Removing and instaling Speedometer Cable and Drive Gear Radio and Antenna Interior Lights. Replacing Interior Light Bulbs Heater and Controls (without ait conditioning) Heater Core, Replacing and Adjusting Heater Controls Fresh Air Biowor Heater and Controls (wth air conditioning) Heater Core. Replacing and Adjusting Heater Controls Checking Vacuum System Seat Betts Inspecting Seat Betts. 10 " " 12 2 12 4 4 14 Instaling or Replacing Seat Belts Child Restraint Tethering 4.7 Front Seats Heated Seats, 48 Rear Seats. 49. Headliner (Scirocco only) Doors 5.1 Door Assembly Interior Tim Window Regulator Window Guides. Weatherstripping Handles and Locks 5:2 Central Locking System, Bi pressure System Troubleshooting Removing and Instaling Door Activators. Bi-pressure Pump Rear Lid Activator Gas Tank Flap Activator Offset Grommet, 53 Side Mirrors ‘Manual Remote-Control Mirrors. ElectricHeated Remote-Control Mirrors . Exterior. 61 Headlights ‘Aiming Headlights. 62 Tallight Assembly 63 Side Marker and Front Turn Signal Lights 64 Trim, Bumpers, and Body Removing Front Body Parts and Gri, 4 15 18 16 16 7 RBssesess BRRRFSS SISERRR12-2 BODYAND INTERIOR Removing and installing Body Trim Removing and installing Bumpers Hood Lock and Cable. Rear Lid ‘Sunroot 7.4 Removing and Installing Sunroot Removing and Installing Sunroof Guides, Cables, and Trim 7.2. Adjusting Sunroof Fit ‘Sunroot Height Adjustment Sunroot Parallel Adjustment. . Convertible Top 8.1 Front Header 8.2 Eccentric Adjustment 8.3 Window Adjustments ‘Adjusting Front Window Fit ‘Adjusting Rear Window Fit. |. Body Assembly Materials... ar 28 29 20 a 31 4 35 $8 se a7 37 10, Air Conditioning (A/C)... 10.1. System Description. Safety Features 10.2 Inspections and Tests. Checking Refrigerant Charge 10.3 Air Conditioning Specifications 11. Cabriolet Power Windows. 12. Power Convertible Top . Emergency Operation Bleeding the Hydraulic System. . Checking and Correcting Hydraulic Oil Level Component Removal and Installation. TABLES Bulb Application and Part Numbers b. Body Assembly Materials .....2..2s0cceree ©. Air Conditioning Specifications 2 888888 £HGGK BUGBoDYAND INTERIOR 12-3. Body and Interior Introduction ‘Scirocco and Cabriolet unitized-body construction yields body structures that are exceptionally strong and light, This light weight contributes to the outstanding combination of performance and fuel economy. During manufacture, the various body panels and subassemblies, plus @ number ‘of smaller prassed-steel panels and plates, ara joined by electric welding. Because few screws and other fasteners are used, fewer rattles are likely to develop. The ride is quieted further by the _appication of sound-dampening materalto the floor plates and the body panels. Itis important to ensure that a car suffering collision damage is repaired properly. Special ‘equipment and methods are required to properly straighten the unitized body structure and retain of restore its designed-in structural integrity. Athough all body panels are available as replacement parts, replacement panels must be butt-welded to the undamaged parts of the body after the damaged panels have been cut away. Proper assembly procedures and mate- fials must be used to ensure that the repaired sections are still adequately protected against corrosion. Refinishing requires the correct materials and an experienced professional to apply them under the proper conidtions. Because of these special considerations, detailed information conbody repair and assembly is beyond the scope ofthis manual This section covers a varity of body and interior components that may require mechanical attention during the life ofthe car, either for repair or for access to other components and sys- tems. Also see ELECTRICAL SYSTEM. If you lack the skils and experience, tools and ‘equipment, or a sutable workplace for servicing or repairing any parts of the body and inte Cf, we suggest thet you leave these repairs to an authorized Volkswagen dealer or other qual- ified and properly equipped shop. We especially urge you to check with your authorized Volkswagen dealer before beginning any repairs on a car which may be covered wholly or in part by any of the extensive warranties issued by Volkswagen United States, nc. WARNING — ** Boginning with 1990 models, the Cabriolet is ‘equipped with a drver-sce airbag, * Serious personal injury can result if airbag ‘components are handled improperly or without adequate safoguards ‘+ Thoroughly read tho Cautions and Wamings at th front of this manual and in SUSPENSION AND STEERING before beginning any work on {an alrbag-oquipped car,12-4 BODY AND INTERIOR 1. GENERAL DESCRIPTION 4.1 Instrument Panel and Instrument Cluster ‘The padded instrument panel houses the ventilation and heating system. if necessary itcan be removed using ordinary hand tools, The instrument cluster can be removed separately. For electrical information see ELECTRICAL SYSTEM, 41.2 Seats, Seat Belts and Interior ‘The front seats are inaividually mountedto the floor. Folding bench-style or split rear seats are bolted to the floor. Both styles are easily removed for access to the rear seat belt ‘mountings and the fuel gauge sending unit All interior trim is designed to be removed using ordinary hand tools. 1.3 Ventilation, Heating and Air Conditioning Fresh air enters the flow-through ventilation system through hood vents and the fresh-air plenum infront of the windshiold, It passes through the heater core and, on cars with air condtion- Ing, the evaporator. Interior air exits through vents in the body. A three-speed or four-speed fresh-air blower assists airflow. The ventilating air can be heated in order to warm the car's interior or, on cars with air conditioning, cooled and de-hurmid- ified. In very hot conditions the interior air can be recirculated for maximum cooling by the air conditioning system. 1.4 Body Unitized-body construction means that there is no separate ‘frame. The sheet metal structure forms a rigid passenger com- partment, with large front and rear crumpla zones for energy absorption in the event of acollsion. See Fig, 1-1. With front wheel drive, there is no driveshaft tothe rear. In- stead the longitudinal hump in the front floor serves to ‘strengthen the body. It also houses the shift linkage, exhaust system, parking brake cables and brake lines. |. Unitized constuction of Cabriolet body Sorocoo ie For corrosion protection, the body steel is specially treated and given a mult-layer finish. Seams are sealed using a PVC ‘compound. The body is undercoated and all interior cavities are flooded with a hot wax. 2. MAINTENANCE Volkswagen specifies checking the operation of the heating ‘and ventilation system as a part of routine maintenance. See LUBRICATION AND MAINTENANCE for the prescribed maintenance intervals, 3. TROUBLESHOOTING This section covers a variety of components and systems, ‘80 specitic troubleshooting is included with repair information. For help when troubleshooting electrical problems, including wiring diagrams, see ELECTRICAL SYSTEM. Also see the: discussion of electrical troubleshooting in FUNDAMENTALS. 4. INTERIOR This section cavers removing and installing interior parts Repairs to interior electrical components are described in ELECTRICAL SYSTEM. Information concerning interior door tim, door locks, window controls and other mechanical parts of the door can be foundin 5. Doors. WARNING — + Boginning with 1990 modbls, the Cabriolet is ‘equipped with a diversi airbag. * Serious personal injury can result It sirbag components are handled improperly or without adequate safeguards. * Thoroughly read the Cautions and Warnings at th front of this manual and in SUSPENSION AND STEERING before bogining any work on ‘an alrbag-equipped car. 4.1 Instrument Cluster and Instrument Panel Removing and Installing Instrument Cluster ‘The instrument cluster can be removed for service or repair Using ordinary handitools, wthout removing the instument panel, To remove instrument cluster (Scirocco only): 1, Disconnect the negative (~) battery terminal 2. Remove the steering wheel as described in SUSPEN- SION AND STEERING, 3, Remove the instrument cluster tim by removing the two screws shown in Fig. 4-1.Fig. 441. Screws (trons) to be removed for terval of 4. Free the instrument cluster by removing the screw shown in Fig. 4-2. Tip forward, but do not fully remove, the cluster, and remove the speedometer cable and any vacuum lines from the rear ofthe cluster. To remove the ‘cable, pinch the retaining tabs shown in Fig. 43. Dis ‘connect the two instrument cluster wiring hamess con- nectors and remove the instrument cluster. W) 10 be removed to Hee instrument Fig. 4-3. Spoodoretor cabo andreianing a -queezed o remove cable fom BopyANDINTERIOR 12-5 Installation is the reverse of removal ‘To remove instrument cluster (Cabriolet only): 41, Disconnect the negative (—) battery terminal 2. Remove the steering wheel as described in SUSPEN- ‘SION AND STEERING. ‘3, Remove the heating and ventiation control knobs from the contro! head by puling them straight out, and then remove the contro! head trim plate. 4, Remove the instrument panel storage tray by snapping it ‘out, of, on models so equipped, remove the radio as described below in 4.2 Radio and Antenna. Pry out the ‘wo switch tim rings shown in Fig. 44, Fig. 4-4. Instrument pane removed itch tim tinge (A, B) to be 5. Remove the six screws shown in Fig. 45 that secure the instrument panel trim plate. Pull the trim out slightly, press out the panel switches, and then remove the trim, 6. Free the instrument cluster by removing the two screws: Cn either side of the cluster. Tip forward, but do not fully remove, the cluster, and remove the speedometer cable12-6 BODYAND INTERIOR from behind by pinching the retaining tabs. See Fig. 4-3 Then disconnect the hamess connectors and remove the instrument cluster. Installation is the reverse of Removing and Installing Instrument Panel Atte first removing the instrument cluster as described above, the instrument panel can be removed or access to the heating and ventilation system and other components, WARNING — Serius uty can reaut if aitag components aro handlodiproporor without adoqiato safeguards ‘See the Gauitons and Wamings at the front of tis ‘manus andin SUSPENSION AND STEERING bo fore beginning any work an an aitbag-equippod car To remove instrument panel (Scirocco only): 1. Remove the left storage bin. Tit it down and remove the screws shown in Fig. 4-6. Remove the left lower trim panel by removing the clips and screws. See Fig, 4-7 7 ry Fig. 4-6. Screws (trans) to be omoved for removal ot 2, Remove the right lower shelf by removing the screws shown in Fig. 48. Remove the right lower trim panel by removing the clips shown in Fig. 4-9 and then puling the Panel off ofits guides. Remove the ventilation air ducts ‘rom the instrument panel vents Fig. 4-8. Sorows (a shel 3. Remove the control knobs from the heating and venta tion control head by puling them straight out, and re- ‘move the trim plate. Remove the screws shown in Fig. 4-10 and pull the lower console back slightly. Remove the screws for the upper console shown in Fig. 4-11, pull the console out slightly, disconnect any electrical con- nections to the console, and then remove the upper console. 4, Disconnect the heater cable as shown in Fig. 4-12. Remove the instrument panel mounting screws. One screw is behind the panel as shown in Fig. 413, two are inside the glove box as shown in Fig. 4-14, and four are at either end of the panel as shown in Fig. 4-18. To remove the instrument panel, side it tothe right off of its mounting guides. Installation is the reverse of removalBoDYAND INTERIOR 12-7 Fig. 4-10 Fig. 4-11, Fig. 4-15. sanel mounting so rument pane! Two Fig. 4-12. Heator cath12-8 BODYAND INTERIOR ‘To remove instrument panel (Cabriolet only): 1. Remove the screws that secure the heating and venti: tion control head, shown in Fig. 4-16, Fig. 4-18, Bots and nus that hokd knee ta ght" ils (of bad Left side af kneebar is sia Fig. 4-16. Retaining screws (1) for heating and vendiaton ‘omot head 2, Remove the ashtray. Remove the four retaining scrows for the center console and move the console back slighty, 8. Remove the two instrument panel ar vents. Use a scrow- ‘river to press inthe retaining springs shown n Fig. 4-17, and pry the vent out Fig. 4-19, Insument pane! hares clsconnected and screw Fig. 4-17. Insiweent pane air vont ing removed. Press down on relahing springs (arts) an pry 4. Remove the kneebar by removing the eight nuts and bolts at either end. See Fig, 4-18. Remove the left and right lower trim panels from underneath the instrument ppanel by unciipping them. Fig. 4.20. natnment panel mounting moter e ‘stobe temoved panel (1) andtromblow pane! 2 Installation is the reverse of removal. Torque the bolts and nul for the kneebar to 21 Nm (15 ft 1b) Disconnect the wiring harness connector and the screws shown in Fig. 4-19 and Fig. 420. Pull the instrument panel off of Is retaining clips and remove ito the right,Removing and Installing Speedometer Cable and Drive Gear On automatic transmission cars, the cable mounts directly to the transmission with a union nut. On manual transmission cars, the cable and drive gear mount as shown in Fig. 4-21. Cars with an oxygen sensor (OXS) mileage counter have two cables, one fromthe tranemiseion othe counter on the firewall and one from the counter to the speedometer. To remave the cable, first disconnect the battery negative (-) terminal. Remove the left]owerinstrumentpaneltrimas described 'n Removing and installing Instrument Cluster. Disconnect the cable from the speedometer as shown earl in Fig. 4-3. Hokddown bot Basket Greta BODYANDINTERIOR 12-9 (On cars equipped with the factory-installed radio prep kit, the wiring is accessible after removing the racio trimplate, See the wiring diagrams in ELECTRICAL SYSTEM for help in identifying the wires and connectors. To replace the roof-rmounted antenna on Scirocco 16V ‘models, the headliner must be removed as described in 4.9 Headliner, 4.3. Interior Lights A lighting failure may be caused by a blown fuse, especially it more than one bulb appears to have failed. Check and, if necessary, replace fuses as described in ELECTRICAL SYS- TEM. Table a lists interor bulb applications and their part ‘numbers. Dashboard lights and their replacement are covered. | in ELECTRICAL SYSTEM, | 1 Table a. Bulb Application and Part Numbers | | =} 2 Bib Ww PartNo US. Trade No. iieror done | N17 7202 a Drive u | © “compartment | N17 7202 an os Center stop l (N17 7532 168: fe used on cre wth manual When replacing the cable on a manual transmission car, pullthe drive gear off ofthe old cable, install a new circip, and push the drive gear onto the cable until the circlip is visible through the hole in he gear. Position the circlip gap 180° from the hole in the gear. To prevent premature failure of the new cable, position tsothat its free of sharp bends. Do not grease the speedometer end ot the cable, 42 Radio and Antenna Factory:installad radios are removed with Volkswagen spe- cial tool WW 160 radio removal clips (order no. TVO 160.000 90, ZEL). First, disconnact the battery negative (-) terminal. Push the clips into the holes on either end of the radio face plate until they cick into place, then use them to remove the radio. Re- move the tools before installing the radio. Make sure that the rubber mount atthe rear ofthe radio is properly engaged. WARNING — Do not use # computer memory saver fo maintain battery power to an antithot ado. Using such a ‘oo! mi keep the airbag systom charged and may ‘cause accidental activation ofthe aihag, ‘cauTion— Wit an ant-thot rao, mako sure tal you knowtho corect rao actvaton code befor dsconnecing tho battery orromeving te rac, Entering to wrong ‘code when powers restored may lock up the racko land render it inoporabl, even the comoct code is later entered, Replacing Interior Light Bulbs ‘Always tum off the ignition before replacing a bulb. Avoid leaving fingerprints on the bulb and reflector. Fingerprints evaporate when the glass gets hot and can dim the light or reflector. ‘To replace the dome light bulb, press against the spring clip Indicated in Fig. 4-22 and withdraw the assembly. Press the assembly back into position after installing the new bulb, ees Fig. 4-22. Spring clip (arow) that hols interior dome ight a heaciner ‘To replace the luggage compartment light bulb, use a small flat blade screwdriver to pry out the light assembly as shown in Fig. 4-28. Install the end with the wiring connector frst, and press the assembly back into postion.12-10 BODYAND INTERIOR ‘To replace any one of the three center stop light bulbs, remove the bulb housing by pressing the small clips on either Side of the assembly inwards to separate the housing from the lens. After instaling the new bulb(s), press the bulb housing into postion. 4.4 Heater and Controls (without air conditioning) The components and controls ofthe heating and ventilation system without air conditioning are shown in Fig. 4-24. The ‘heater box contains the heater core, as well as two flaps 4-23, Luggage compartment it assembly beng «e- erated by cables connected to the top two levers of the eae Tt) ‘control head in the instrument panel. One flap regulates airflow Fresh ai ower Seaing gastet Heater valve cable — Heater box Fig. 4-24, Exposed vew of vontiation and heating systemto the floor vents, and the other regulates flow to the defrost vents. A thd cable attached to the bottom lever of the control head operates the heater valve. When the valveis open, engine. ‘coolant flows through the heater core and heats the incoming, air. Soe ELECTRICAL SYSTEM for electrical tests ofthe blower motor. If moisture is leaking into the front foot well area of the ‘passenger compartment, check the heater core as described below. Also, check the plastic drip tray at the base of the windshield in the engine compartment. It may be cracked, allowing water to leak into the vantlation system fresh air inet. Heater Core Coolant leaking visibly into the passenger compartment is a sign ofa faulty core or heater hose. A sweet, antfraeze odor in, the car's interior, or a constantly fogged windshield may also indicate a faulty core. Inspect the carpet and the area near the floor vents for any signs of moisture or coolant. A leaking heater ‘core may be caused by overpressurization ofthe cooling sys tem. See COOLING SYSTEM for more information. When replacing the heater core or a hose, the coolant must first be drained as described in COOLING SYSTEM. The heater core can be pulled out ofthe side ofthe heater box after the cover is unclipped and the hose clamps are loosened to remove the heater hoses. Replacing and Adjusting Heater Controls ‘The heating and ventilation control head is shown in Fig. 4.25, ‘Control head Cable retring clp, —Detost fap Foor vent tao conta over Blower Sven Fig. 4.25. Hoatng and vention control head usecton cars whoa air conctionng, BODYAND INTERIOR = 12-11 ‘To remove control cables, first remove the control head trim plate and the lower instrument panel trim panels as described in 4.1 Instrument Cluster and Instrument Panel. For defrost © floor vent cables, remove the retaining clip that holds the ‘cable conduit to the control head, then remove the cable from the flap and the control lever. For the heater valve cable, ‘move the retaining clips from the control head and the heater valve, and then remove the cable. To install and adjust detrost or floor vent cables, place the ‘control levers in the OFF position. Install the cable onto the control lever and the control flap. Making sure that the flap isin the closed positon, install the cable retaining clip, When replacing the heater valve, make sure thatthe engine is fuly cool. Clamp the heater hoses close to the valve to prevent coolant oss, and piace a container under the valve to Gatch any coolant that may leak out when the hoses are disconnected. Disconnect the control cable from the valve. Alter the new valve is installed, check the coolant level as dscribed in LUBRICATION AND MAINTENANCE, Toinstall and adjust the heater valve control cable, place the control lever in the closed position. install the cable onto the control head and install the retaining clip. Then install the cable ‘onto the heater valve and, making sure that the valves closed, install the other retaining clip. See Fig, 4-26. Fig. 4-26, Heater vave convo cable beg hte ar acit- 1c With cable securedto cortel head, move ave to Cf poston (A andrea etaring cp Bh Fresh Air Blower ‘The fresh air blower motor is located atop the heater box. ‘The motors reached from the engine compartment by remov- ing the plastic drip tray at the base of the windshield, and then removing the plastic screen covering the fresh air inlet. To remove the motor, unciip the series resistor from its bracket ‘and remove the screw under the resistor. See Fig. 4-27. Tithe motor up and out and uncip the resistor wiring. See ELEC- TRICAL SYSTEM for oloctrical tosts of the series resistor.12-12 BODYAND INTERIOR Fig. 4-27. Insiated positon of fash al blower and series resister. Motor mouning screw (art) 3 10 4.5 Heater and Controls (with air conditioning) ‘The components and controls ofthe heating and ventilation system with air conditioning (A/C) are shown in Fig. 4-20, (facing page). The heater box contains the fresh air blower, the heater core, and the evaporator forthe A/C system, The control flaps for air distribution are operated by vacuum servos, which are controlled by the vacuum distibutor attached to the top lever in the control head. The top lever also actuates the AIC thermostat switch to turn the air conditioning on and off. The ‘bottom lever of the contol head is attached to the heater ‘control valve by a cable, When the valve is open, engine ‘coolant flows through the heater cove to warm the incoming ai. I there is moisture leaking into the front foot well area ofthe passenger compartment, check the heater core as described below. Also, check the plastic drip tray at the base of the windshield for cracks that may allow water to leak into the heater box fresh air inlet. Finally, check the evaporator drain, hose for clogging and correct installation. The hose routes A/C. system condensation from the bottom of the heater box to, underneath the car. Itis mounted behind a small cover on the left side of the passenger foot wel. Insufficient heater or ar conditioner output, or ar flow that does not correspond to control lever position may be caused, by problems with the vacuum system. Check the vacuum, system as described below before assuming that another com- ponents fauity, Fora description ofthe airconditioning, and for, testing procedures, see 10. Air Conditioning, See ELECTRI- CAL SYSTEM for electrical tests of the blower motor. Heater core Coolant leaking visibly into the passenger compartments a sign ofa faulty core or heater hose. A sweet, antifreeze odor in the car's interior, or a constantly fogged windshield may also indicate a faulty Core, Inspect the carpet and the area near the floor vents for any signs of moisture or coolant, Aleaking heater ‘core may be caused by overpressurization of the cooling sys: tem, See COOLING SYSTEM for more information. When replacing the heater core or a hose, the coolant must first be drained as described in COOLING SYSTEM. The ‘heater core can be pulled out ofthe side of the heater box after the cover is removed and the hose clamps are loosened to remove the heater hoses, Replacing and Adjusting Heater Controls The control head for the heating and ventilation system with air conditioning is shown in Fig. 428. The top control lever is ‘connected to the vacuum distributor to control ventilation air flow. The bottom lever is also connected to the vacuum dis- tributor, and to the A/C thermostat switch and the bowen cable for the heater valve. Replacement and adjustment of the heater valve and cable are covered in 4.4 Heater and Controls (without air conditioning). Test the vacuum distributor as described below in Checking Vacuum System, Fig. 4.28. venulaton system wih air condoning, ‘To tree the control head for replacement of the vacuum distributor or A/C thermostat switch, pry off the contro! head trim plate and then remove the control head mounting screws. Make note of vacuum hose connections when replacing the vacuum distributorBODYAND INTERIOR 12-13 ‘Vacuum S650 or Lesa sen ra as te = to Engine sm system layout inset) of systom with a condition: ing, Vacuum gauge is used for testing vacuum system,12-14 BODYAND INTERIOR To replace the A/C thermostat switch, frst pull the capillary tube from the evaporator. Then remove the switch from the ‘control head. Install the new switch and adjust it as shown in Fig, 4-90. Insert the capillary tube from the new switch into the evaporator to a depth of approximately 180 mm (about 7 in.) Fig. 4-90, Getiom view of A‘ contl head shaving tala ten of XC thermos tc, Push ever 4 war ‘wich stop, tur suitor counterclockwise to stop (bia aro then tighten mounting sew, Checking Vacuum System Engine vacuum operates the vacuum servos. If the control head cannot properly direct air flow, check fora faulty servo or leaks in that part of the vacuum system, The servos can be reached by removing the left and right lower instrument panel trim panels. i none of the servos respond properly, there is a problem withthe vacuum supply or the vacuum distributor. To test the vacuum system, install a vacuurn gauge as shown earlier in Fig. 4-29. Run the engine until the gauge reads at least 15 inches Hg, Move the air distribution lever and the temperature control lever all the way tothe right, and stop the engine. if the gauge reading falls within one minute, check for leaks in the vacuum hoses, the vacuum reservoir, the check valve or the vacuum distributor. If the gauge reading stays the same but one or more of the vacuum servos has re- tracted, then the vacuum distributor or the control head is. faulty. See Replacing and Adjusting Heater Controls. 46 Seat Bolts Seat belts should be periodically inspected. I they have to be removed for any reason, itis important that they are reinstalled correctly. For problems with the seat bet warning ightbuzzer systemsee ELECTRICAL SYSTEM. Inspecting Seat Belts Inepect front and rear belt webbing. Replace belts that have broken or pulled threads, cut loops at the belt edge, bowed of twisted webbing, faded areas, orcuts. On airbag-equippedcars (Cabriolet from 1990), the front belts are designed to elongate and absorb energy in a crash, Check these belts to determine ‘whether or not they have been elongated. See Fig. 4-31 Pull each belt out fully and let it retract. It should move ‘smoothly in both directions. Checkfor dir, grease or other con- taminants on the webbing. Clean belts using only a mild soap solution recommendedtor cleaning upholstery or carpet. this isnot adequate to clean the belt, should be replaced. WARNING — * Soat belts should almays be replaced asa sot itthay have been stressed in acolision. * Donot bleach ordye seatbelt webbing Webbing that ie severely fad wil not moot strength ro- ‘quirements and must be replaced Replace the bettif the buckle cover is cracked, i the latch release button is loose, or if it does not latch securely. Re- place corroded mounting hardware, ‘Check the belt retractor mechanisms to see that they lock. {At the front, tug sharply on the belt while extending it. At the rear, extend the belt, let several inches feed back into the re- tractor, then tug sharply on the bel. In both cases, the retractor should lock. Replace a belt the retractor does not lock, Note — For front automatic belts itis ifficlt with this fost to apply enough force to the actuate the inartia roel and lock the retractor. Forfront automatic belts, the retractor should also lock with ‘change in vehicle motion, such as while brakingtromaspeed ‘of 5to 15 mph. Replace a bet i the retractor does not lock. Fig. 431. On aitag equppod cars, measie from mounting toedge of tim 2. as greater than 40 mm .6in) ‘ho bot has elongated anc must be replaced, Installing or Replacing Seat Belts The retractors must be securely anchored. Belt mounting points only must be free to swivel when the bolts are tight. Torque mounting bots at 35 to 47 Nm (26 0.35 I.)WARNING — For maximum protection from injury, donot inter. ‘change buckle and retractor assemblies with those designated for otter seating postions or ‘other modes Child Restraint Tethering For child restraint systems with a tethering strap, Volkswa- {gen recommends the anchoring points shown in Fig. 432 for Scirocoos, and Fig. 4-33 for Cabriolets. Pull back the carpet strip to expose the anchoring point before driling an 8.5 mm, (42 in) hole. Cuta 20 mm (ein. hole in the carpetand glue it back. Use the mounting hardware shown in Fig. 4-34 or Fig 4-5 to mount the strap. Seats can be mounted on either the left or the right side. Fig. 4.32. Scirocco anchoring paint for chia restrain tether ing strap. Onl hole where two lines intersect (1). Dimension ais 451 mm (17 in), Dimension Bis 30 mm (1346) from inner edge of shel Fig. 4-39. Cabvoitanchoxng point for hid restraint eter ing strap, Dal Pole where two ines intersect. 1). Dimension ais 225 mm (8% in). Diension Bis 35 mm (1 34) fom iner ede of shat, BOpy AND INTERIOR 12-15 Fig. 4-84. Scrooco mounting haraware for chid restraint anchor A. Hex bolt tie part no. N 010 244 11 Spacer ing2 is par no. 811 857 819. Washer 8s, partne NOI 670 11, Hexnutispart no. N11 08 8 — Fig. 495. Cabriolet mounting hardware for chit restiain. anetex A Hx bot 1 is part na. N 900 245 01 Spacer 2's part no. 808 019 825 B. Washor 3 is part no. NO15 401 4, Hex rus is part no. NOT 008 18, WARNING — To assure maximum protection, follow manufac: turer insiuctons when instaling@ chi restraint system. caurion— art numbers are for reference only. Aways Consultan authorized Volkswagen dealer forthe latest parts information NoTE— It the mounting hardware provided with the chil seat does not ft the anchor mounting, Contact the chi seat manufacturer for suitable arts. Volkswagen specications are for maxi- ‘mum occupant protection. 4.7 Front Seats ‘Toremove a ront seat, first slide the seat all the way forward. Pry up the end of the track cover or remove the screw and side the cover off of the track as shown in Fig. 4-98. Remove the ‘track stop from the rear ofthe other ral. On models with heated seats or electric height adjust, disconnect any electrical con- ectors beneath the seat, Remove the acorn nut, the washer, and the bott from the front guide shown in Fig. 4-97, and12-16 BODYAND INTERIOR release the retaining rod from the seat while siding the seat ‘towards the rear of the car and off is tracks. Installation is the reverse of removal Fig. 4-96, Front soa rack cover removed rom retaining cp, ‘Sie cover of ack in deeetion af arom T2AOiO. Fig. 4.87. Acorn ut (A) and retaining rod (B) 1 be removed when remoung seat Heated Seats (On modets with heated seats, check the electrical circuit to the seats as described in ELECTRICAL SYSTEM belore as- ‘suming that a heating element is faulty, ‘To replace the heating elements, remove the seat as de- sorbed above. Separate the backrest wire from the seat wiring ‘connector. See Fig. 4-38. Remove the backrest from the seat ‘cushion by removing the left and right trim pieces and the hinge screws. Remove both seat covers and heating elements, Lay the new heating elements against the seat without wrin- kling the elements. install the seat covers and route the wire hhamess as shown in Fig. 4-38 and Fig. 439 4.8 Rear Seats omove the rear bench seat cushion by removing the two Screws shown in Fig. 4-40 and then pulling the cushion out, toward the front. Fig. 4-38, Routing of wis fochosted seals beneath driver's seat cushion. Passenger seat ie miror mage, We 1is backrest element wire, 2 sea element wire, 3 is weng grommet, 4 is wing cin. is connecter. Fig. 4.99. Routingot backrest wie forhested seat. Wie runs Delweon seat cover tensioning wres and seat frame () ey. Fig. 4-40. Rear bench seat cushien screws (antaws) to be removed. Side cushion out toward ont‘Toremove the Cabriolet rear seat backrest, fold the backrest forward and then remove the two backrest mounting bolts. ‘To remove the Scirocco rear bench seat backrest, fold the ‘backrest forward, unclip the locking lug shown in Fig. 4-41, and remove the backrest, Fig. 4-41, Locking ug A to be pushed in direction of arow for removal of Sorocco reer seat backroe To remove the Scirocco spit rear seat backrest, fold the backrest forward and uncip the release cable shown in Fig 4-42. Remove the mounting screws from one side of the backrest, and remove the locking lug from the other as shown, above in Fig. 4-41, then remove the backrest. Fig. 4-42, Scrocco rear sit seat backrest release cable (arton) and mounting screws () 4.9 Headliner (Scirocco only) ‘The headliners a one-piece molded panel thats clipped in place. It is removed after removing the headliner trim panel (Clean the headliner using only mineral spits, isopropanol, or ‘a mild cleaning solution. BODY AND INTERIOR = 12-17 ‘CAUTION — To avoid damaging the headliner, do not lt acetone, paint thinners, or metal primerjpotyure- thane (a solvent used to install the windshield) contact To remove the headliner trim panel, frst remove the sun’ visors by removing the mounting screws from the swivels ‘mounts. Next, remove the sun visor retaining clips as shown in Fig. 4-43. Unctip the dome light and disconnect the wiring. On cars with a sunroot, remove the sunroof erank handle and trim panel. The headiiner trim panel can now be removed by sliding tout toward the front. Fig. 4-43. Retaining clip being remeved, Remove mounting screw (1), thon twist cp 90" n action of artow. Doors ‘The rear half of each door hinge is welded to the door. The ‘ont hinge half is bolted to a bracket welded to the car body. Hinge pins are available as replacement parts. The only ad- Justment point of the door hinge is the center mounting bot. When removing a door, mark the hinge halves so that the door can be reinstalled in its original position ‘To remove a door, remove the mounting screws for the door ‘check rod bracket. Use an impact driver to loosen the hinge bolts. Support the dor, then remove the bolts and the door. ‘On models with electric mirrors or central locking system, frst remove the mirrors as described in 5.3 Side Mirrors, and remove the vacuum hose and wiring for the lock actuator as described in §.2 Central Locking System, cauTion— tthe door is not supported when the fst bon is removed, the second hinge may bend or break. Install the door using the marks made prior to removal f a replacement door is being installed, it should contact the ‘weather seal evenly, and the lock should work smoothly. Set the hinge bolts with an impact driver.12-18 BODY AND INTERIOR 5.1 Door Assembly The interior tm, glass, handles, locks, mirrors and internal ‘components can all be reached without removing the door Make sure that the drain holes at the bottom of the door are open. On reassembly the plastic moisture barrier shouldbe well sealed, without creases. If necessary, reseal i using a non- hardening adhesive. Also see 11. Cabriolet Power Windows. Interior Trim ‘The interior trim must be removed for access to the internal door components. No special tools are required for the proce- dure. To remove trim: 1. Unscrew and remove the lock button, 2. Pry out the trim plate forthe inside door lever. ‘3. Remove the tim for the remote control rear view mirror. 4. Remove the window winder handle by unclipping the ttim and removing the mounting screw. 5. Remove the pull handle or armrest. On Scirooces, re- move the upper and lower trim and remove the two ‘screws, then pull the handle down. On Cabriolets, re move the two screws, turn the armrest 90°, and then remove it 6. On Sciroceos, remove the loudspeaker trim panel 7. Remove the door trim panel. On Sciroccos, remove any additonal screws at the edges and face ofthe trim panel (On Cabriolets, check for any additional screws that may secure the panel and remove them if necessary. Then gently pry the panel off ofits retaining clips. Installation is the reverse of removal. Apply thread locking ‘compound to the window winder handle screw before install- ingit. Window Regulator To remove the window regulator, first remove the interior ‘im panel and the plastic moisture barrier from the door as described above. ‘On Sciroccos, remove the glass mounting bolts and lower the window into the door. The bolts are reached through an ‘access hole near the top of the door. See Fig. 5-1 for the location ofthe mounting bolts for Scirocco window regulators. When instaling the regulator, install but do not fully tighten the window glass mounting bots, raise the window fully, then lower it and tighten the bots, ‘move four bolts (araws), then unelipreguatr torn point A (On Cabriolets, lower the window and remove the screw that holds the regulator to the front bottom edge of the window. Remove the seven bolts that hold the regulator to the door, then slide the regulator out while disengaging the rear regulator uide from the window. Adjust the window regulator stop after the regulator is installed. Align the top of the window as de- scribed in Convertible Top. Then, with the window raised, press the regulator stop against the regulator and tighten the Window Guides Both Scirocco and Cabriolet door window guides are re- placeable if there are air or water leaks. In either case itis necessary first to remove the door trim as described above for ‘access to the guide mounting screws. To remove Scirocco rear guides, remove the screw and bott shown in Fig. §-2. To remove Scirocco front guides, remove the screws and bolt shown in Fig. 5:3. Fig. 5:2. Screw (Hack artow) and bolt removed for removal of uid.BODY AND INTERIOR 12-19 upper part of the Weatherstripping is available as a separate ploce, part no. 155 837 915A/916A, and is installed as shown in Fig. 56, Fig. 5. Scrous (1, 2) and bol (8) to be removed for re moval of Sciooco window tent gud. ‘To remave Cabriolet window guides, first remove the top part ofthe vent window weatherstripping as described below in ‘Weatherstripping, Remove the screw shown in Fig. 5-4, then remove the two hex head screws in the door panel Fig. 5-4, Screw underneath weatherstipping ta be ern for removal of Cabriolet window guide, Weatherstripping To remove Cabriolet vent window weatherstipping, first remove the screw shown in Fig. 55, then pull of the weather. stripping. If the upper part of the door weatherstripping is in poor shape, itis not necessary to replace the entire piece. The ‘caurion— Part numbers are for reference only. Aways ‘consult an authorized Volkswagen dealer forthe latest pars information. Fig. 6-5, Screw for upper part of Cabsilet vent window \weathorstinpng being removed, Fig. 5-6 Replacorent door weatherstioping (A) being in staled, Butt together new part wth oft weather tapping (B). Handles and Locks ‘The outside door handle must fist be removed for access to the door lock cylinder. To remove the handle, pry out the trim sirip, then remove the two retaining screws and slide the handle off in the direction shown in Fig. 7. Installation is the reverse of removal12-20 BODYAND INTERIOR Fig. 5-7. Expioded view of door handle mechan. For re ‘moval, handle sides of in deecton of arom ‘To remove the door lock, lock the door lock with the door ‘open, then remove the two lock mounting screws and pull the. lock partway out, Hold the lock actuating lever in its turnec-out position as shown in Fig. 5, then detach the lock from the pullrod and sleeve. removed. Actuatng lever (A) is by Sceewcener inserted through To instal the lock, use a screwdriver to hold the actuating lever at 90" angle as shown in Fig. 5-9, and reattach the lock. to the locking knob sleeve and the pulrod as shown in Fig, 5-10. Then install the mounting screws, Fig. 5-8. Lock actuating lever Abang held 90" ange using soreneivesfr instal Fig. 5-10. Door lock boing instalad, Atuating lover attached to pul (B), are locking knob lever is attached to Sleeve (©), ‘To remove the inside door actuating lever, first remove the {door rim panel and door lock as described above. Remove the strap trom the panel and slide the door lever assembly from the door as shown in Fig. 5-11. Installation is the reverse of re- moval Fig. 5-11. Door actuator lever being removed Remove stan (1) and side assembly in recon of arom 5.2 Central Locking System The central locking system consists ofa special bi-pressure Pump in the luggage compartment, connected by vacuum hose to lock activators at the passenger door, atthe rear ld, ‘and at the gas tank flap. When the key is turned in the driver's door lock, the master activator tums on the pump to supply pressure to open the locks, or vacuum to close them. This heading covers only the removal and installation of the mechanical parts, and troubleshooting of the b-pressure sys. tem. Ifthe pump does not run when kay is turned, the problem ‘may be electrical, Troubleshoot the pump and the master ‘activator as described in ELECTRICAL SYSTEM, Nore— I the central locking system has not been op- fetated for an extended period, the Key may have to be turned several times betora the sysBi-pressure System Troubleshooting ‘When the key is tured in the master activator, all locks ‘should be activated within 2 seconds, A faultis indicated ithe pump runs longer than § seconds, or if the pump runs, but none of the locks activate. Troubleshooting should be carried ‘out in the sequence given here, even if only one activator is suspected of being faulty. The replacement of faulty compo- ents is covered below under separate headings To troubleshoot: 1. Remove the bi-pressure pump from its housing as de- scribed below, but do not disconnect it. 2. Clamp the hose as shown in Fig. 5-12, Activate the pump using the door key. if the pump runs longer than § ‘seconds, ether the hose from the pump is leaking or the pump is fauty If the pump shuts off within 5 seconds, remove the clamp and continue testing Fig. 5-12. Bi-pressure purp being tested wih hove camp att 3. Clamp the hose as shown in Fig. 5-13. ifthe pump runs longer than 5 seconds when activated, the right door activator or the hose to it is faulty, If the pump turns off within § seconds, remove the clamp and continue testing Fig. 5-13. Fight door actualor being tested wih nose clamps installed, Bopy AND INTERIOR 12-21 4, Clamp the hose as shown in Fig. 5-14. the pump runs. longer than 5 seconds when activated, then the gas tank flap activator or the hose to I is faulty. f the pump turns off within 5 seconds, then there is a fault either in the activator for the rear lid, or in the off-set grommet that ‘connects the rear lid and the body, or in the vacuum hose. Fig. 5-14. Gas lank fap being testod with hose clamp in stale, Removing and Installing Door Activators To remove a faulty activator, frst remove the door tim pane! land moisture barrier as described in §.1 Door Assembly. Remove the activator retaining screws and unhook the con- necting rod shown in Fig. 5-15. When removing the master activator from the driver's door, first disconnect the battery {ground cable, and then disconnect the electrical connector. When removing the passenger door activator, disconnect the vacuum hose. Installation is the reverse of removal. Fig. 5-18. Phantom view ol master activator instalation, Pas senger door activator is sia12-22 BODYAND INTERIOR Bi-pressure Pump The bi-pressure pump is located in the luggage compart- ‘ment on the right side, behind the trim panel and the container {or the washer fluid. When removing the pump, frst disconnect the negative (—) battery terminal. Remove the retaining stap, land then remove the pump from its housing. Disconnect the electrical connector and the hose, and remove the pump. See Fig. 5-16. Installation isthe reverse of removal Fig. 5-16. 6: pressure pump and rated component, Rear Lid Activator ‘The rear lid activator is shown in Fig. 5-17, To remove the activator, open the lid and remove the inside trim panel by turing the fasteners 90°. Loosen, but do not remove, the ‘activator mounting bolts. tis necessary to unscrew the rear id, lock and the mounting bracket forthe rear wiper for clearance toremove the activator. Disconnect the vacuum hose trom the ‘activator and disconnect the connecting rod atthe lock. Instal- lation is the reverse of removal ‘A Actiyator c ® Fig. 517. Fear lid actuator being removed. Remove vac 1am hose (A) and connecting rod at ©. Gas Tank Flap Activator ‘The gas tank flap activators shown in Fig. 5-18. Itis located in the right-hand side of the luggage compartment, behind the trim panel and the container forthe washer fluid. To remove the ‘activator, dil out the three rivets and disconnect the vacuum hose. instalation is the reverse of removal. New rivets are avallable from an authorized Volkswagen dealer. 37-219 Gas tank flap actnator being removed. Dril out ‘ves (tows) ane disconnect vacuum hose, Off-set Grommet ‘The off-set grommets the vacuum connection between the car body and the rear ld forthe rear id activator. ithe grommet ‘must be replaced, install the new part as shown in Fig. 5-19, Fig. 5-19. O-set grommet, showing conect instalation, 5.3 Side Mirrors ‘Both manual remote-control side mirrors and electric side mirrors are easily removed using ordinary hand tools. In either case, the interior door trim panel must first be removed land the moisture barrier peeled back as described in 5.1, Door Assembly.Manual Remote-Control Mirrors ‘The manual remote-control mirrors for Sciroceo and Cab let are shown in Fig. 5-20 and Fig. 5-21. With the door trim, panel removed, remove the lock nut for the remote contol knob and remove the mounting screws for the mirror. Lift the ‘mitror away from the door, guiding the knob and its cables, through the door. On Sciroocos, the mounting screws for the ‘mirror re located behind the smalltrim panel tthe front comer, of the door window. Installation is the reverse of removal HiMounting screw | | {__Romese conte hrob we “ nt} Fig. 5-20, Exploded view of Scirocco manual remote-controt Fig. 5-21. Phantom vw of Cabriolet manual remote contol Electric/Heated Remote-Control Mirrors ‘The procedure for removal of electric remote-control mirrors 's similar to that of manual miors described above. The only ditference is that instead of a remote control knob, tis the mirror wiring inside the door that must be disconnected, Hf the mirror wil not operate, check the electrical circuit as described in ELECTRICAL SYSTEM before assuming that the ‘motor is faulty. It is not necessary to remove the mirror 10, replace the motor. “To replace the mirror motor, frst remove the mirror glass as ‘shown in Fig. 5-22. Take note of the wiring connections to the ‘ass. With the glass removed, remove the motor mounting, BODY ANDINTERIOR 12-23 serews shown in Fig. 5-23. Take note ofthe wiring connections. Installation is the reverse of removal. With the miro glass in place, insert the screwdriver and tum the lock ring the opposite ‘way to engage the detent. Fig. 5-22, Electric miror glass being removed. Inset sorevs liver to engage natch i Jock ring, then move Sorowarver in Brecon of arow fo unlock glass. Fig. 5-23. Motor mounting sorews (aon) 10 be removed. ). EXTERIOR ‘The exterior body parts and trim discussed under this head- ing are fastened with conventional fasteners, and are easily removed using ordinary hand tools. A thorough knowledge of ‘automobile body repair is not needed to perform the procedures. 6.1 Headlights ‘The Scirocco and Cabriolet use sealed beam headlights. ‘See Fig. 6-1 and Fig. 6-2. A retainer holds the headlight to the adjusting frame, and two screws are used to aim the head- lights. fa headlight falls, the entire sealed beam unit must be replaced.12-24 BODYAND INTERIOR f forward and disconnect the wiring. Orient the new lens such that the part ofthe lens marked UP or TOP, or else the single ‘adjusting lug is uppermost. It should not be necessary to aim ‘the headlight the adjustment screws have not been touched. However, itis a good idea to check headlight sim as described below, Fig. 6-2. Cabriolet headlight assemiby, Screws fr retainer ‘3 shown by arows, Soren for mounting fame fe at A, and screws for acusmert are at 8 Replace a sealed beam unit with the headlights off. Remove the radiator grile as described in 6.4 Trim, Bumpers, and ‘Body. On Sciroccos there is an addtional molding below the headlights, attached with two screws, that must be removed. Remove the screws from the retainer and remove it, The ‘Screws for the Scrocco are shown in Fig. 6-3. The screws for the Cabriolet are shown above in Fig. 6-2. Pull the headlight Fig. 6-3. Scrocco neadight retainer screws (A). Screws also shown for mounting frame (artows) and adjust mentAiming Headlights ‘Special adaptors are supplied with the car's tool Kt to aim the headlights. Headlight aiming using the adaptors should be carried out by an authorized Volkswagen dealer or other qual fled shop. Headlight aiming can also be done as described below without any spacial tools, but the results will nt be as exact Nore — Check your state laws to see if headlight adjust ‘ments must be made by a licensed shop. Some States may also have diferent aiming speciica tions from those described here, To aim the headlights, postion the car on a level surface, 25 foot (approx. 7.6 meters) from a vertical wall. The gas tank should be half full and the tire pressures should be correct, ‘Tum the headlights to low beam. With a person in the driver's, ‘seat, the low bears must be in the areas indicated in Fig. 6-4 Hre-aimingis necessary, remove the radiator rim grile and use ‘a Philips head screwdriver on the height and side-to-side adjusting screws to move the headlight. \ NFoBSC Fig. 6-4. Headight airing target on vertical wall Low beam ght infenaty ars are at 4. Line 2 at eight o neadlight cones, Lie is car conten, Lnes 3 and are dsiane from centerine to centers of eadighis 6.2 Taillight Assembly All rear bulbs and the talight lens are replaced from the luggage compartment. Replacement of the center brake lightis, ‘covered in 4.3 Interior Lights. On Sciroccos, replace a fui tllight bulb by first removing the bulb holder. Pinch the two clips on the top and bottom of the holder shown in Fig. 6-5 and remove the holder. Press the bulb in and twist to remove and install it, Make sure that both lips are engaged and that no wires are pinched when the holder is installed. Boby AND INTERIOR 12-25 L Fig. 65. Scirocootalignt bulb holder. Pinch clips (arows) to remove. Replacement tum-signal, stop-ight and back-up ight bubs ae part no. NO17 732 2 (US. trade no. 1073). Tallght bulbs are part no. N01? 7192 (US. tage no. 6). (On Cabriolets, replace a faulty bulb by first removing the bbulb holder. Depress the tab to remove the bulb cover, and then depress the tab to remove the holder. See Fig. 6-6. Press the bulb in and twist to remove and install it Fig. 6-6. Cabriolet bub holder, Press tab 110 remove bub ‘over, Prass lab 2 fo remeve holder. Replacement tube are same as for Sckooco. See Fig. 65, ‘The tailightIens is replaced by removing the four nuts in the luggage compartment that hold the lens to the body. Pull the lens off the car wit its gasket. 6.3 Side Marker and Front Turn Signal Lights Toreplace a Scirocco front side marker ortum signalbulb or lens, open the hood. Pullbackthe rubber capfromthe light and squeeze the lugto remove the bulb holder. See Fig. 6-7. Press the bulb in and twist to remove and install it. To remove the lens, frst remove the bulb holder, then remove the lens mount- ing screws12-26 BODY AND INTERIOR Fig. 67. Sorocco font sklemarker andturngaligh, row ts to bub hide ug Lens mouritng Serews ae 21 A (one screw not sb in stration), Rapace rent so rarer turn signa bub is okswagen pa re. NOI 7382 (US. rade no. 1034) ‘To replace a Cabriolet side marker bulb, remove the two ‘mounting screws and pull the ight assembly away from the fender. Pull back the rubber cap, then press the lugs on the bull holder outward to release the holder. To replace a tun ‘signal bulb or lens, remove the lens mounting screws and the lens. Do not overtighten the lens mounting screws, or the lens may crack. 6.4 Trim, Bumpers, and Body For corrosion protection, the fenders, hood, and trunk id are assembled with zinc plates which act as anodes, and with a. sealing tape between mating surfaces to prevent moisture rom, becoming trapped. See Fig. 6-8. The plates are part no. AKL 381 035 50, and the tape is part no. D 001 900. NoTE— The plates and tape are installed as part of the corrosion warrant. Hn doubt about warranty protection, consult an authorized Volkswagen Sealer Fig. 6-8, Correct ita on body parts for ma Removing Front Body Parts and Grille ‘The front radiator grile is held in place by a combination of screws and spring clips. Scirocco grilles and 1985-1987 Ca- briolet grilles are in 8 pieces. 1988 and later Cabriolet giles are one-piece. To replace a fonder, first remove the wheelhouse liner, ‘bumper, and bumper trim as described below. On Cabriolets, remove the side marker light. Carefully use a heat gun and razor knife to cut through the PVC coating along the A-pilar where the fender meets the body, then remove the mounting bolts. Scirocco fenders are held by 13 bolts, while Cabriolet fenders are held by 9 bots. the fender does not pull away with ‘a moderate amount of effort, check again for any fasteners stil, installed. Excessive force wil damage the fender. During in Stallation, install the zinc plates and sealing tape as shown above in Fig. 6-8. cauTion— Use extrome care when applying heat to the body to avoid blistering the paint or iscoloring the PYC body costing. Torepiace a wheethouse liner, support that comer ofthe car securely on a jack stand and remove the wheel. Remove the ‘mounting screws and pul the liner down and out. See Fig. 6-9. Installation is the reverse of removal. Torque the wheel bolts to 110 Nm (80 fb) after lowering the car to the ground, Fig. 6-9. Location of fasteners (arrows) that secure wheel house liner on Soracoos. Cabricit wheahouse inors are een, bul are secured wh only seven To remove the hood, frst mark the hinge plate locations on the hood for reinstallation. Loosen the mounting botts, then with ‘helper supporting the opposite side, remove the bots. Install the original hood by aligning the matching marks made earier. If instaling a new hood, loosely install the mounting bolts and adjust the hood so that it contacts the body evenly. During installation, install the zinc plates and sealing tape as shown above in Fig. 6-8.BODY AND INTERIOR = 12-27 Removing and Installing Body Trim caution — Part numbers are for reference only. Alay’ rely Body trim includes the wheelhouse trim, body side moid- ‘On 8” authortoed Voltewagen dealer for the ler Ings, stone guards, and front and rear spoilers. A rivet gun is. fest and most accurate parts formation, necessary when installing some wheelhouse trim. Replace- ment rivets are available from an authorized Volkswagen dealer. ‘There are two types of wheelhouse trim on Sciroceos. The ‘basic rim is secured with screws and rivets. FulHlength wheel- house trim on 16-valve models is secured with screws and adhesive. To replace Scirocco 16-valve wheelhouse trim: 1. Remove the bumper. Remove the wheel NOTE— Tho illustrations used here show the front vheethouse rim only. The procedure is similar for te rear tim, 2, Remove the wheelhouse liner as described above, then remove the trim mounting screws. 3. Partially remove the spoiler trim where it meets the wheelhouse trim by cutting through the adhesive. See Fig. 6-10. Then partialy remove the rocker panel trim in the same manner. Fig. 6-12, Wheehouse trm being instaled. Tubing presses against unper edge of tm, 6. The remainder of installation is the reverse of removal. Use the same adhesive to join the wheelhouse trim tothe ‘spoiler and the rocker panel tim. Allow the adhesive to Fig. 6-10, Sooior rim being partly removed rom wheel ‘set for at least ten hours before removing the tape. house tem by cuting adhesive wih kate (ar ‘There are two types of wheelhouse trim on Cabriolets. Trim 4. Remove the wheelhouse molding by cutting itaway with on 1985 through 1987 models is secured by screws. Trim on knife as shown in Fig. 6-11. With the molding removed, 1988 and later models is secured by screws and rivets. To ‘rim the adhesive on the fenderto aheightof 1.0mm (vs remove 1988 and later Cabriolet wheelhouse trim, fst remove in). Remove all other traces of adhesive using $M solvent. the body side molding as shown in Fig. 6-13, then remove the trim as shown in Fig, 6-14, 5. Install a bead of adhesive on the wheethouse trim, using adhesive part no. AKD 476 KDS 05 or similar. Then install ‘To remove the stone guard, pry the fastening studs on the the molding onto the fender as shown in Fig. 6-12. uard away from the retention clips as shown in Fig. 6-15,12-28 BODY AND INTERIOR + =m Fig. 6-13. Cabrciot body side moicing boing temaved, Re ‘move screws (1), ten tt meicing Up and out ct ips @ Fig. 6-14. Vincohouso trm being roroved. Dil out ets (3) ard remove screus (4, 8) \— Fastaning stu Stone guarc (ema) Fig. 6-15. Sione guard atachment to fender. ‘The spoiler for the Scirocco rear lidis shown in Fig. 6-16. To remove the spoiler, open the lid and remove the bolts from the holding angles. Use a pulty knife to cut the bonding adhesive land sealant. Remove the remaining sealant on the lid toa level (of 1.0 mm (sin). Apply sealant (part no. D 008 100) around the holding angles for water-proofing, and apply adhesive (part ‘No. 0001 200) tothe bottom of the spoiler. the spoilers being installed on a new piece of glass, first use the spoiler as a ‘template to locate the areas on the glass on which to apply ‘sealant primer (part no. D 009 200). ‘caurion— Part numbers are for reference only. Alvays rely ‘on an authorized Volkswagen dealer forthe lat- fest and most accurate parts information. Fig. 6-18. Scirocoo rea it spo Removing and Installing Bumpers ‘The front and rear bumpers are mounted on solid brackets bolted to the frame, with guide brackets attached to the body. To remove a bumper, simply unbolt the brackets from both sides of the car frame and pull the bumper straight of. See Fig. 6-17, Fig. 6-18, Fig. 6-19, or Fig. 6.20. On 1988 and later Cabriolet models, itis necessary frst to remove the fender mountings for the bumper cover as shown in Fig. 6-21. instal lations the reverse of removal. Torque the mounting botts to. 90 Ni (66 tb.)Fig. 6-17. Locato Iron bumper (sown th lights removed for cia). © Fig. 6-18. Location of mounting bali (arraws) for Sceocco ear bumper, inside luggage compartment. Op Fig. 6-19. Location of right-side mounting bots for Cable front bumper (arrows). Left sie aim. Bopy AND INTERIOR 12-29 Fig. 6-20. Location o gt-side mounting bots or Cabicet ‘ear bumpe (aos, Left de is sea Fig. 621. Location of bumper cover mounting rivets in wheahouse Hood Lock and Cable ‘The hood lock is held in place by rivets, and is easily replaced once the cable is removed from the lock. If the lock and Jockpin are not aligned, adjust the lockpin plate on the hood by loosening the plate mounting bolts. The hood lock cable can be adjusted by loosening the cable lock screws as shown below. Fig. 622 shows the routing ofthe Scirocco hood lock cable. To replace the cable, disconnect it from the lock by loosening the cable lock screw shown in Fig. 6-23, and remove the cable from its retaining clips. Remove the mounting screws for the ‘cable release lever in the passenger compartment, then draw the cable through the firewall. Installation is the reverse of removal. Connect the cable to the lock without any tension, tighten the lock sorew, and wind any excess cable around the12-30 BODY AND INTERIOR Fig. 6:22. Sotccco hex eves (12 lock cable rousing with guide Fig. 623. Lock screw (arom Fig. 6-24 shows the routing ofthe Cabriolet hood lock cable. To replace the cable, disconnect it from the lock by loosening the cable lock screw and removing the clip shown in Fig. 6-25, Remove the cable from its mounting clips. Remove the mount- ing screws for the cable release lever in the passenger com: partment, then draw the cable through the firewall, Installation, is the reverse of removal. Connect the cable tothe lock without, any tension, Fig. 624, Cabrolet hood lock cable routing and mounting ches (A) Fig. 6-25. on of locking sere or Cablet hood lock Cable (arow), and cp to be remeved (8, Rear Lid ‘The rear lid locks for Scirocco and Cabriolet are shown in Fig, 6-26 and Fig. 6-27. Both locks are secured to the lid with ‘screws, The lock and the position ofthe bottom edge ofthe rear lid is adjusted by moving the striker plate. To adjust, loosen the striker plate mountings screws just enough so that plate can be moved by hand, but with some effort. Close the id and adjust it until the bottom edge is even, then open the lid and torque the striker plate mounting screws to 10 Nm (87 in. 1b), exons —, Laten — siker plate er Fig. 6-28. Exploded view ofsop, 100k linkage ice rear ict ook Fig. 6:27. Exploded view of Cabr ‘To replace a license plate bulb, remave the screws that hold the lens to the lid, Press in and twist the bull to remove and, install it Tighten the lens screws just unl they are snug to avoid ‘cracking the lens. Replacement bulbs are part no. NO17 717 2 (US. trade no. 1816), 7. SUNROOF ‘The sunroot is operated by a set of cables which pull the sunroof panel along guide rails when the crank is turned. The sunroof can be adjusted without removing it rom the car, but, replacement of the sunroat liner or components such as the cable assembly require sunroof removal. the sunroof leaks or slicks, adjust it as described in 7.2 Adjusting Sunroot Fit before deciding thatit needs to be removed trom the car. Leaks ‘may also be caused by clogged drain hoses. The front hoses, lead from the A-pillar into the space between the front fender and the door. The rear hoses lead to the rear section ofthe side panels. Clean the hoses with a length of flexible cable, such as. ‘an old speedometer cable. Work down from the top ofthe front hoses, and up from the bottom of the rear hoses. 7.1. Removing and Installing Sunroof ‘The only special tool needed to remove the sunroof is a length of wire, Bent into the position shown in Fig. 7-1. tis used 10 unhook the sunroof tim spring, BobDYANDINTERIOR 12-31 Fig. 7-1. Special too fer detaching survoo rim sping. ‘mension ais 300 min (12). To remove: 1, Open the sunroof. Using the tool shown above in Fig 7-1, detach the spring from the sunroof trim as shown in Fig. 7-2, then close the sunroot 2. Push the sunroof trim back from the front guide, then remove the trim rod from the left and right guide rails. ‘See Fig. 7-3.12-32 BODYAND INTERIOR > a Fig. 7, Locaon of suc mouring screws (aows) on front guide (1, Remove scews fom both sce Fig. 7-2. Sexing 1) being detached rom suneoot tin (2) wth m7 pot 6. Crank the sunroof forward untithe guide pins forthe rear uide sie out ofthe guide plate, and then remove the sunroot. See Fig. 7-6, 12 Fig. 7-6, Roa guide pin (1) ng cranked out of Quid Fig. 7.3. Tim rod (1) being removed rom gui a pate Installation isthe reverse of removal. It may be necessary to 3. Disconnect the water deflector plate lever from the left loosen the front guide plate screws as shown in Fig. 7-7 for and right guides as shown in Fig. 7-4 instalation of the water deflector plate lever. Adjust the sunroof as described in 7.2 Adjusting Sunroof Fit, then attach the trim, panel as shown in Fig. 7-8 4 se boing laconnected. Remove Fig. 7-7. Mounting screw for font npin @) andr defector ave (8) cut to ice pate (1) to be sened when inslaing water deflector p screw when fished, 4. Remove the right and left sunroof mounting screws from the front guide as shown in Fig. 7.BobDY AND INTERIOR 12-33 Fig. 7-8, Release detent sping (aro) for water dtlctor Fig. 78, Suro tim boing insaled. Win suroo! open, close im panel ners isa gap atensroxnaiy 10-15 mm tein) at then push im Up (A ae forward (8) Engage ten sping ust PO wen rise Removing and Installing Sunroof Guides, Cables, Fg. 710, Mounting screw lo fo wind clear acti and Trim ing od ft, Remove stew fr oer sige ase This heading covers the removal ofthe sunroot parts in cluding the wind deflector. the front guides, the front cable 5: Remove the front cable guides by removing the screws {uides, the roar guides with cables, the water deflector plat, shown in Fig. 7-11, then remove the two cover plates and the guide ras. from ether side as shown in Fig. 7-12. To remove: 1. Remove the sunroof as described above. 2, Move the water deflector plate to the rear after pushing down on the detent spring shown in Fig. 7-8 3. Crank the rear guides to the rear and push the front guides back for access to the wind deflector actuating rod mounting screws. See Fig. 7-10. Remove the actu ating rod screws and the deflector mounting screws, and remove the deflector 4. Remove the sunroof crank and cable dtive as shown below in Fig. 7-18. Fig. 7-11. Front cable guide mounting sere (arraws} tobe removed.12-34 BODY AND INTERIOR 7.2 Adjusting Sunroof Fit ‘There are two adjustments for the sunroof: height adjust- ‘ment and parallel adjustment. incorrect height adjustment may ‘cause wind noises at high speed, water leaks, or scratching of the sunroot panel. incorrect parallel adjustment may make the ‘sunroof ficult to operate, or prevent it from closing squarely, Sunroof Height Adjustment Fig. 7-16 shows the corect height adjustment of the sun- root. Height is adjusted at the front and rear guides after the ‘sunroof trim has been detached from the sunroot and pushed ‘back as described in 7.1 Removing and Installing Sunroot, Fig. 7-12. Cover pate (1) tbe removed fom both sides 6. Remove the guide rail mounting screws shown in Fig 7-13, then remove the remaining sunroof parts in the folowing order: the front guide, the rear guides with cables, the water deflector plate, the trim panel, and the guide rails. E 4 Fig. 7-18. Corroct hight aqustment of suncat Adjust the front height at both sides of the front guide member as shown in Fig. 7-16. To adjust the rear height, fist remove the water deflector plate levers from both sides as shown above in Fig. 7-4, then adjust the height as shown in Fig 7-17. Reinstall the deflector lever plate as shown in Fig. 7-7, and reinstall the trim panel 0-18 B Fig. 7-13. Guide ral mounting screw fro) to be removed from athe sce, Installation is basically the reverse of removal, When the A ‘cover plates and front cable guides are installed, loosely install, the screws, then push the cover plates against the guides as s shown in Fig. 7-14 and tighten the screws. Adjust the sunroot as described below when finished. . frac Fig. 7-16, Surroo! font height aclustment for both sides Loosen screws A and tue screw B 10 adjust belgt. Tighten screws A when fished. Fig. 7-17. Survoo! roar height being adusied by loosening screws (atows) Tighton screws when finshed, Fig. 7-14. c front cable guides being in stale. Lightly push guides (@) aganst o plates (1) anc igen caver plato Seren.Sunroof Parallel Adjustment ‘The sunroof paralle! adjustment aligns the rear guides so that they operate parallel to each other. The adjustment is, ‘made using a pai of inexpensive tools, Volkswagen special oo} ‘no, 3060 ( order no. TOS 060 000 60 ZEL). The sunroot panel ‘must be removed as described in 7.1 Removing and Install ing Sunroof to make the adjustment ‘To adjust sunroot parallel operation, turn the sunroof crank handle until it locks, then remove the handle and the cable rive, See Fig. 7-18, Use the special toots to adjust the position, of the rear guides as shown in Fig. 7-19, then reinstall the cable rive and recheck the measurement. Install the sunroot panel when finished, Fig. 7-18, Sunvool crank hance and cable dive (1) wh mounting screws (arto) Header Latch Tersionng cabo Main wearing BobyY AND INTERIOR 12-35 a) Fig. 7-19. fear sunroof guides being adjusted using Volkswagen special tool 3060. Dimension Bb should be 62 £05 mm (2 "in. cauTiON— Always move the rear guides togothor 10 the front or rear when adjusting them. Do not move ‘no forward and ono back, or vice vorsa 8. CONVERTIBLE TOP ‘The Cabriolet is a modification of a basic two-door unitized body. When the convertible top and its mounting trame are added, extra body-strengthening members anda steel rollbar are also added to the body structure. The configuration of the Convertible top is shown in Fig. 8-1. For information about the ower-operated top available since 1991, see 12, Power Convertible Top. Eccentric Fig. 8-1. Converse top mounting frame. Top adsiment Points are at front latches and Ie and right12-36 BODY AND INTERIOR ‘A.number of adjustments can be made to the convertible top and to the windows in order to ensure proper weather sealing. In general, if the top is dificult to open or close, or if atts, water leaks, oF fluttering noises come from around the top's front header, the front part of the top needs to be ad. usted. If there are rattles or air leaks around the rol bar, then either the frame eccentric or the windows must be adjusted, Make all adjustments withthe car on level ground. 8.1 Front Header Hf there are air or water leaks at the front edge of the top, adjusting the front latches may cure ther. Ifo, then the top ‘seal may need replacing, The latches are adjusted after loosening the adjustment locknuts shown in Fig, 8-2. With the latches undone, turn the latch hooks clockwise or counterclockwise so that the top ‘contacts the header evenly and with reasonable pressure when the latches are closed. Tighten the locknuts when finished. Fig. ©:2. Locknut (ara) tobe loosened for convertible top header latch acusimert ‘To replace the top seal, drill out the two rivets at either end Of the seal and pry the seal off. Clean off any old adhesive. Apply adhesive as shown in Fig. 8, then push the new seal Into place and install new hollow rivets. Finally, seal the area ‘shown in Fig, 8-4 with a silicone sealer 8.2 Eccentric Adjustment The two eccentrics on ether side of the convertible top frame are used to adjust the fof the top against the roll bar. To, adjust the fit, open the top halfway and use a wrench as shown, in Fig, 85 totum the eccentric one way or the other. Close the top to check the fit of the weatherseal against the roll bar. Readjust as necessary Fig. 8-3, Convortibie hac sea being replaced. Apply ad hesive in shaded area on both sdes Replace ret (arrow) on beth sides. Fig. 8-4. Siicone sealer being applied to header seal, D- ‘mension A on both ses of tame is apprommatly 200 mm (7 % i), Fig. 85. Eccentic being ued with wrench for top aust8.3 Window Adjustments Three adjustments are made to the tront and rear side windows to ensure a weather tight fit and smooth operation, The adjustments include the window ft against the convertible top seal, the parallel fit of the window in its frame, and the fore-and.aft fit of the windows against the side seals. The correct ft of the windows against the convertible top seal is, shown in Fig. 86. Front window adjustments are made with the door tim panel removed as described in 8.1 Door Assembly. Rear window adjustments are made with the rear seat removed as described in 4.8 Rear Seats, and with the side tim panel unclipped, = = J Fig. 8-6, Cutaway vew of proper ft of window glass against convoribie top seal Adjusting Front Window Fit Front window ft against the seal is adjusted by loosening the bots shown in Fig. 8-7 and moving the channel in or out as necessary. Tighten the bolts when finshed. Fig. 8-7. Bots (arow) 0. loosened jor adjustment ol ont incon fit against top ee. BODY AND INTERIOR 12-37 Front window parallel itis adjusted by loosening the bolts ‘shown in Fig. 88 to move either the frontor the rear ofthe glass Lup or down. Tighten the bolts when finished. Fig. 88. Gots to be loosened for adsting front window parale ft. Loosen bots A to adjust rear of glass, ‘and bolls B to adjust font of case ‘The fore-and-aft fit of the front windows against the front ‘uide channel is adjusted after the bolt shown in Fig, 8-9 is loosened. Check the movement of the window glass after adjustment, and readjust if necessary. —=P. we g Fig. €-9. Bot 1 be loosened (1) for fore-anc-ftachusiment front window Adjusting Rear Window Fit Rear window ft against the top sealis adjusted by loosening the bott shown in Fig. 8-10 and moving the glass up or down ‘as necessary. Tighten the bott when finished, “Toadjust rear window parallel it, first remove the convertible top hinge cover as shown in Fig. 8-11. Adjust the fit by loos- ening the botts shown in Fig. 8-12 and moving the rear of the glass up or down as necessary. Tighten the bolts and replace the cover when finished.12-38 BODY AND INTERIOR ‘The fore-and.aft ft of the rear window is adjusted after Yoosening the bolt shown in Fig. 8-13. Roll the window up and. down a few times to center it in the channel, then tighten the bot Fig. 8-10. Bot to be loosened (1) for adustment of roar window fit against top seal Move glass up or ‘own (arons} as necessary Fig. 8-13. Bott to be loosened (1) for adjustment of rear window fre-end at fi. Move window as neces sary (@rows) for smooth operation, 9. Bopy ASSEMBLY MATERIALS The assembly materials listed in table b are specified by ‘Volkswagen for use in body and interior repairs. ‘CAUTION — 51-8011 Volkswagen part numbers listed in this manual are provided for reference only. Always check with an Fig. 8-11. Screws to be removed (arrows) for removal of ‘auhonized VoKswagen dealer Parts doparmant Comertble top hinge cover forthe most accurat and up-to-date information, Table b. Body Assembly Materials ‘Application Fastoning| windshield {part no, D 000 702) Adhesive activator {part no, 0 000 701) Gluing intarorleathoretia | Synthetic adhesive — (part no, D 001 101) Ghiing carpet, rubber, felt | Universal adhosive and fabric to painted metal_| (part no. 0 001 200) Gluing door seals Profil rubber adhesive (part no. D 002 100) Fastening protective inerte | Two-sided tape door (partno. AKL 440 025) ‘Rahesive cleaning solution | Cleaning solution (part no. D 009 400 1) Fig. 6-12. Botts tobe loosened (1,2) for parallel adjustment Primer for paining Paint primer ~ of rear window. {partno, D 008 300) ‘Sealing gaps in bolts, cables | Original plastc soalant and wires to panels (partne. D 001 400)